Ceiling tiles

ABSTRACT

According to one embodiment of the present invention, a ceiling tile may provide for suspending and stiffening leading to the following performance characteristics: ( 1 ) ease of suspension and seismic compliance; ( 2 ) ability to suspend thin and low internal bond strength materials, in addition to standard materials; ( 3 ) accommodation of wood movement while maintaining panel flatness; ( 4 ) stiffening of panels to panel edge; ( 5 ) alignment of panels within concealed suspension T-Grid without additional components; and ( 6 ) ease of fabrication.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application Ser. No. 61/625,620 which was filed on Apr. 17, 2012. The complete disclosure of the above-identified patent application is hereby incorporated by reference for all purposes.

BACKGROUND

The present invention relates to ceiling tiles, for example, those made of decorative wood or other materials. The invention further relates to suspending and stiffening such tiles.

Suspended wood ceiling panels are a growing architectural market segment. The suspension systems of these panels have a number of features that are typically desired by customers and/or may be required by regulation, such as the ability to use large panel sizes (larger than about 2′×2′), concealed suspension T-grid, accessibility, seismic compliance, and ease of installation.

In addition to these issues relating to suspension, other design considerations may be taken into account, such as the inclusion of stiffener bars, and the ability to suspend panels constructed from cores which complicate or preclude the use of mechanical fasteners.

Adverse climate conditions may affect the performance of ceiling tiles, particularly wood tiles, by causing panels to shrink and swell which may affect flatness. Allowing stiffening closer to the panel edge than previously possible may improve flatness performance. Incorporating stiffening and alignment functions within the suspension clips may ease manufacturing. Allowing the suspension of a wide variety of panel core materials, including very thin and low internal bond strength materials may also be desirable.

Technology For Suspending Tiles

Large wood tiles may be hung with a lift-and-shift seismic suspension system. Typical systems effectively meet the suspension and seismic requirements. Suspension of non-standard substrates may require other suspension systems. The lift-and-shift suspension may also present limitations on the use of stiffener bars.

This lift-and-shift system typically uses four components that interact with standard T-Bar flanges. A grooved clip is seated on one side of the T-Bar flange, while a locking clip holds it in place. A stepped clip allows the panel to be rotated and fixed into place, while a safety strap attaches to the T-Bar web and provides seismic compliance. Alignment of the panel within the T-Bar grid is accomplished with wood blocks which interface with the cross-tees.

Challenges with suspending non-standard cores: Clips are typically attached to the panel using screws. While this works well for standard cores such as particleboard and Medium Density Fiberboard (MDF), the use of very thin materials, such as hardboard, as well as materials with a low internal bond strength, such as mineral board present challenges.

Challenges with stiffening panels close to edge: Stiffener bars typically are not extended to the edge of the panel because of interference with the suspension clips. In some climate conditions this can result in panels warping and curling at the perimeter to an extent dependent on the severity of the climate conditions. This is believed to result from the movement being transferred to the panel edges.

Additional clips may be required to attach stiffeners: Stiffener bars are typically either attached to the panel directly or attached using hold down clips, which may be placed regularly along the stiffener length. The additional clips typically affect both fabrication time and manufacturing cost. Both of these methods of stiffener attachment rigidly fix the back of the panel to the stiffeners. This does not allow the wood panel to shrink or swell, which can result in stiffener failure.

Additional components may be required to align panels within concealed suspension T-Grid: Wood alignment blocks may be required to be attached separately from the other clips, which may increase manufacturing cost.

SUMMARY

According to one embodiment of the present invention, a ceiling tile may provide for suspending and stiffening leading to the following performance characteristics:

1. Ease of suspension and seismic compliance.

2. Ability to suspend thin and low internal bond strength materials, in addition to standard materials.

3. Accommodation of wood movement while maintaining panel flatness.

4. Stiffening of panels to panel edge.

5. Alignment of panels within concealed suspension T-Grid without additional components.

6. Ease of fabrication.

Ease of suspension and seismic compliance of existing solutions: This system may be designed to incorporate all the advantages of lift-and-shift seismic suspension systems, while providing additional features and benefits. The installation procedures are generally similar or the same, which will benefit installers familiar with the previous system.

Ability to suspend thin and low internal bond strength materials, in addition to standard materials: Suspension clips may be designed with a large bottom surface area, which allows for adhesive attachment to core materials that do not allow mechanical fasteners, such as thin hardboard or mineral board. The clips may include holes which allow attachment to standard particleboard or medium density fiberboard using screws or staples.

Accommodation of wood movement while maintaining panel flatness: Suspension clips may include a notch shaped in the profile of standard commercially available 9/16″ Heavy Duty T-Bar Mainrunner, which can be used as a stiffener. This notch may be loose enough that the clips can slide along the mainrunner, while still restraining vertical motion. This permits the wood panel to shrink and swell, while maintaining the stiffening action of the mainrunner.

Stiffening of panels to panel edge: The stiffener bars may be attached to the suspension clips, the result of which is the effect of the stiffening is spread over a larger area, including at or adjacent to the panel edge. This may be preferred over systems that require stiffeners to be inset to avoid interference with the suspension system.

Alignment of panels within concealed suspension T-Grid without additional components: Grooved clips are constructed with a groove on one side, and a vertical edge on the other side, allowing suspension or alignment depending on the orientation of the clip. The groove allows the clip to be set on the flange of a T-Grid mainrunner. The vertical edge provides alignment of the panel within the T-Grid by acting as a bumper against the cross-tee flange.

Ease of fabrication: By incorporating the suspension clips and attachment of stiffener bars, this system may reduce the number of clips that are attached during fabrication. This allows for reduced manufacturing costs, and more competitive pricing compared to other systems.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of two lift and lock clips, with I-beam stiffeners, aligned at a cross-tee, according to an embodiment of the present invention.

FIG. 2 is a pictorial view of a panel with lift and lock clips according to an embodiment of the present invention.

FIG. 3 is a perspective view of a panel with lift and lock clips according to an embodiment of the present invention.

FIG. 4 is a plan view of a panel with lift and lock clips according to an embodiment of the present invention.

FIG. 5 is a perspective view of a portion of a panel with single step lift and lock clips suspended on a mainrunner flange according to an embodiment of the present invention.

FIG. 6 is a perspective view of a portion of a panel with double step lift and lock clips suspended on a mainrunner flange, and showing a safety strap coupling the clip to the mainrunner web according to an embodiment of the present invention.

FIG. 7 is a perspective view of a portion of a panel with two lift and lock clips, with I-beam stiffeners, aligned at a cross-tee, according to an embodiment of the present invention.

FIG. 8 is a side view of a single-step clip, according to an embodiment of the present invention.

FIG. 9 is a perspective view of a single-step clip, according to an embodiment of the present invention.

FIG. 10 is a side view of a double-step clip, according to an embodiment of the present invention.

FIG. 11 is a perspective view of a double-step clip, according to an embodiment of the present invention.

FIG. 12 is a perspective view of another double-step clip, according to an embodiment of the present invention.

FIG. 13 is a perspective view of a locking clip, according to an embodiment of the present invention.

FIG. 14 is a perspective view of another single-step clip, according to an embodiment of the present invention.

FIG. 15 is a perspective view of the single-step clip of FIG. 14 with an I-beam stiffener inserted, according to an embodiment of the present invention.

DETAILED DESCRIPTION

As depicted in the drawings, a system 20 incorporating an embodiment of the invention may be used with ceiling panels or other tiles 22. System 20 preferably includes four stiffener bars 24 on each tile 22, typically each extending along and adjacent to an edge 26 of tile 22, although other numbers and configurations of stiffener bars 24 may be used.

As shown in FIGS. 5 and 6, system 20 may be used to secure ceiling panels 22 to an array of suspended T-bars 28 at flanges 30. Each ceiling panel 22 typically defines a front face 32 (FIG. 3) and an opposed back face 34 and a first edge 26 a and an opposite second edge 26 b. The first and second edges 26 a, 26 b are preferably configured to be aligned with the suspended T-bars 28 at flanges 30.

One or more clips, for example five clips 36 a, may be coupled to panel 22 along and adjacent to first edge 26 a of panel 22. One or more clips, for example five clips 36 b, may be coupled to panel 22 along and adjacent to second edge 26 b of panel 22. Clips 36 a may be of one type, e.g., having a single step, and clips 36 b of another type, e.g, having a double step, for a lift-and-lock installation at T-bar flanges 30. A locking clip 42 (FIGS. 4 and 13) may be used to lock the panels in place and safety strap 44 (FIG. 6) may provide a restraint if the clips are dislodged from the T-bar flanges.

Each clip 36 preferably defines a channel 38, best seen in FIGS. 8-12 and 14-15. Channels 38 of clips 36 along each edge are preferably aligned with one another. Stiffener bar 24 is preferably inserted in the channels of clips 36 along an edge of the panel. Each edge may include one or more clips, e.g., five clips, and a stiffener bar may extend through each set of clips along each edge, as seen in FIGS. 2-4. Channel 38 preferably allows relative movement of the stiffener bar and the clips. In an alternative embodiment, shown in FIG. 4, clips 36 extend along a center line of panel 22 and another stiffener bar 24 is inserted in the channels of the clips to provide stiffening along that center line.

System 20 may also include an aligning function incorporated into the clips. As best seen in FIGS. 1 and 7, clips 36 may be aligned in two adjacent rows with a cross-tee 40.

Clips 36 with channels 38 allow the stiffener bar, e.g, a small “I” beam to slide, allowing the wood panel to grow and shrink, but maintain acceptable flatness.

Clips 36 may be attached to panels 22 by any suitable means, including fastening with hardware such as screws at one or holes in each clip. Other means include adhesives, or other fastening techniques other than hardware.

Stiffener bars 25 are preferably located as close to the edge of the panel as is practical for each particular embodiment. Stiffening close to the edge is generally considered to be more effective at reducing the warping of the panel.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated. 

What is claimed is:
 1. A system for securing ceiling panels to an array of suspended bars, the system comprising: a ceiling panel defining a front face and an opposed back face and a first edge and an opposite second edge, the first and second edges configured to be aligned with the suspended bars; a first clip coupled to the panel adjacent the first edge of the panel, the first clip defining a channel; and a first stiffener bar inserted in the channel of the first clip, the channel allowing relative movement of the first stiffener bar and the first clip.
 2. The system of claim 1 further comprising a first plurality of clips, each clip defining a channel, the first plurality of clips distributed along the first edge of the panel, and further wherein the first stiffener bar extends through the channels of each of the clips in the first plurality of clips.
 3. The system of claim 2 further comprising a second plurality of clips, each clip defining a channel, the second plurality of clips distributed along the second edge of the panel, and further including a second stiffener bar extending through the channels of each of the clips in the second plurality of clips.
 4. The system of claim 1 further comprising a second clip coupled to the panel adjacent the second edge of the panel, the second clip defining a second channel; and a second stiffener bar inserted in the channel of the second clip, the second channel allowing relative movement of the second stiffener bar and the second clip. 